Method and Apparatus for Sealing Film Bags

ABSTRACT

An adjustable sealing apparatus and corresponding method of use is disclosed. The sealing apparatus has a variable range of motion programmed to accommodate multiple types of sealing motion, including the reciprocal motion and rotary motion. The proposed design uses two sealing jaw units with each sealing jaw unit located on opposing sides of a continuous layered film. Each sealing jaw unit has a sealing jaw coupled to a distal end of extendable linkages. The sealing jaws are extendable to allow the sealing surfaces to engage one another at a plurality of sealing locations along a plurality of sealing paths. Moreover a control unit is communicatively coupled to each of the sealing jaw units and controls movement of the sealing jaw units to engage one another at one or more of the plurality of sealing locations which enables sealing of the film to produce bags.

BACKGROUND Technical Field

The present disclosure relates to an adjustable sealing apparatus andmethod for sealing film. More particularly, the disclosure describes animproved sealing apparatus with opposing sealing jaws, each of which iscapable of moving along one of a plurality of sealing motions to createbags of various form factors.

Background

Vertical fill form and seal machines (“VFFS machines”) are commonly usedto bag particulate products, including, but not limited to, snack foodsthat are particulate in nature. Particulate snack foods include, but arenot limited to, potato chips, corn chips, and extruded snack pieces ofvarious shapes and sizes. These usually enter near the top end of theVFFS machine in measured charges and are each then sealed into a packagethat is formed on the machine, from packaging film, to contain the snackfood charge. The packaging film is most commonly of a heat sealablepolymeric composition. In the heat sealing process, there are severalvariables, but significant among these are the applied pressure of thejaws, the dwell time (i.e. the time that the pressure is applied) andthe seal temperature. The seal temperature is generally determined bythe packaging material. But, the applied pressure and the dwell time areparameters that an operator can manipulate.

In some VFFS machines the package film advances downward around aforming tube where the free ends of the film are sealed together alongthe side of the forming tube and sealed transversely by a sealing deviceas it travels below the forming tube. The partially formed bag having asealed side and bottom end is then filled with the particulate chargeand the top of the bag being formed is sealed with another transverseseal.

In some VFFS machines, the motion of the packaging film is haltedintermittently as the film is being transversely sealed to form the bag.The step of heat sealing requires a finite amount of time to complete.Consequently, VFFS machines of this type are of intermittent operation.

In other VFFS machines, which are of continuous operation, there is ajaw assembly that has a pair of opposed jaws that are each mounted to acommon rail so that they slide on the rail toward each other to closeand thereby seal the film gripped between the jaws, and slide away fromeach other to an open position. In addition, the jaw assembly has avertical rail along which the common rail (with its mounted opposedjaws) can slide up and down. Thus, during operation, the sealingelements on the faces of the opposed jaws move in a “box mode:” inwardto pinch the packaging film between the jaws, and the downward, at thesame speed as the traveling film, while still applying pinching pressureto form the transverse seal. The jaws separate outward away from thefilm once the seal is formed; and then move upward in position for againpinching inward to form the next seal. A point at the leading edge ofeach sealing element traces a locus (“path”) that is a rectangle andthat can be described as a “box.” These box-mode jaws can formtransverse seals while the film moves continuously. Box-mode jawassemblies are relatively heavy but they can apply relatively highsealing pressure, and have relatively high seal dwell time. They can beused with large bags, such as large pillow bags. And, they are useful inmaking formatted bags, including but not limited to single sidedgusseted bags, or double sided gusseted bags, or bags with a base shapedfor standing upright for display. But, they are relatively slow in termsof bags made per minute.

In a variation of the box-mode jaws described above, the jaws may tracea D-shaped locus. These jaws are relatively faster than the box-mode,and can apply moderate seal dwell times, and moderate seal pressure.They are not as capable as the box-mode in terms of the variety offormatted bags that they are suited to making.

In yet other VFFS machines, there are fixedly positioned opposed rotaryarms, one on each side of the packaging film. Each rotary arm carries aheat sealing element to form the transverse seal. These heat sealingelements are convex inboard, presenting an outward curved surface facingtowards the packaging film. (By “inboard,” we mean the side that wouldface the packaging film during operation of the sealing jaws.) Thus, asthe rotary arms rotate, the heat sealing elements on each side rotateinto positions where they register and urge against opposite sides ofthe packaging film as the arms rotate to create a transverse heat seal.The opposed sealing elements contact the film, during sealing, along theconvex opposed surfaces to apply pressure and heat. Further, as therotary arms rotate a point at the leading edge of each sealing elementtraces a locus that can be described as a circle. The VFFS machine is ofcontinuous operation in that the packaging film advances withoutinterruption as the transverse seal of the bag is formed. These jaws areable to operate continuously at high speed in terms of bags/minute. Theyare able to apply very high seal pressure, but for very short dwelltimes. Because of the structure of the rotary jaws, they are notwell-suited to sealing large bags. And they are not suited to makingformatted bags because they spatially interfere with the placement offormers. They are, by and large, limited to pillow bags.

In a variation of the rotary type of VFFS machine, the heat sealingelements are mounted to the rotary arms so that they are able toreticulate to a limited extent so that the faces of the sealing elementsmay be squarely aligned to each other during the formation of the seal.

SUMMARY OF THE INVENTION

In accordance with a first embodiment, a film sealing apparatus isprovided having opposing sealing jaws, each of which is capable ofmoving along one of a plurality of sealing motions to create bags ofvarious form factors. Currently multiple different machines are requiredto seal different types of bags, or a single machine may be used,however, is unable to run at optimal rates for every type of bag. Forexample, a reciprocating machine is able to seal a format bag, but thesystem will not run a standard pillow bag at the same rate. The proposedjaw system of the present disclosure is capable of the reciprocatingmotion but is also capable of a rotary motion at high rates due to thelight weight of the jaws.

The sealing apparatus has a first sealing jaw unit opposing a secondsealing jaw unit, both of which are communicatively coupled with acontrol unit to control movement of the first sealing jaw unit and thesecond sealing jaw unit. More specifically, the sealing apparatus has afirst sealing jaw mounted on a first side of a film path. The firstsealing jaw unit includes a first sealing jaw coupled to a distal end ofa first set of extendable linkages, and also includes a first sealingsurface. The sealing apparatus also has a second sealing jaw unitmounted on an opposite side of the film path. Additionally, the secondsealing jaw includes a second sealing jaw coupled to a distal end of asecond set of extendable linkages, and also includes a second sealingsurface. The first sealing jaw and the second sealing jaw are extendableto allow the first sealing surface to engage the second sealing surfaceusing one of a plurality of sealing paths. The sealing apparatus alsoincludes a control unit communicatively coupled to the first sealing jawunit and the second sealing jaw unit, which controls movement of thefirst sealing jaw and the second sealing jaw to engage the first and thesecond sealing surfaces using one of a plurality of sealing paths.

In accordance with a second embodiment, a film sealing method isprovided that includes the steps of: providing a first sealing jaw uniton a first side of a film path with a first sealing jaw coupled to adistal end of its first set of extendable linkages; providing a secondsealing jaw unit on a second side of the film path with a second sealingjaw coupled to a distal end of its second set of extendable linkages, inwhich the first sealing jaw and the second sealing jaw are extendable toallow the first sealing surface to engage the second sealing surface ina number of potential sealing locations; determining a first sealingpath for the first sealing jaw; determining a second sealing path forthe second sealing jaw so that movement of the first sealing jaw alongthe first sealing path and movement of the second sealing jaw along thesecond sealing path causes the first sealing jaw and the second sealingjaw to meet at any one or more of the plurality of sealing locationslocated along the film path; extending a film along the film path; andsealing the film between the two sealing jaws at any one or more of aplurality of sealing locations.

Other aspects, embodiments and features of the invention will becomeapparent from the following detailed description of the invention whenconsidered in conjunction with the accompanying drawings. Theaccompanying figures are schematic and are not intended to be drawn toscale. In the figures, each identical, or substantially similarcomponent that is illustrated in various figures is represented by asingle numeral or notation. For purposes of clarity, not every componentis labeled in every figure. Nor is every component of each embodiment ofthe invention shown where illustration is not necessary to allow thoseof ordinary skill in the art to understand the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the invention are setforth in the appended claims. The invention itself, however, as well asa preferred mode of use, further objectives and advantages thereof, willbe best understood by reference to the following detailed description ofillustrative embodiments when read in conjunction with the accompanyingdrawings, wherein:

FIG. 1 depicts a bagmaker configured with a pair of sealing jaws inaccordance with an illustrative embodiment.

FIG. 2A depicts a pair of opposing sealing jaw units in accordance withan illustrative embodiment.

FIG. 2B depicts a perspective view of a sealing jaw unit, for example,the first sealing jaw unit according to one embodiment.

FIGS. 3A-B depicts a set of linear actuators used to actuate secondarylinkages in order to rotate the sealing jaw surface in accordance withan illustrative embodiment.

FIGS. 3C-D depicts a set of rotary actuators used to actuate secondarylinkages in order to rotate the sealing jaw surface in accordance withan illustrative embodiment.

FIGS. 4A-D depicts a simplified schematic of a number of potentialsealing jaw path and pattern examples.

FIG. 5 depicts a schematic view of the invention in the context of afilm sealing environment in accordance with an illustrative embodiment.

FIG. 6 is a flowchart of a process for sealing a bag in accordance withan illustrative embodiment.

DETAILED DESCRIPTION

Novel aspects of the embodiments disclosed herein recognize the need foran improved film sealing apparatus and corresponding method for sealingfilm bags. The sealing apparatus includes opposing sealing jaw unitsthat can accommodate variable sealing motions that can be adjusted toaccommodate different bag types without the expense of limiting sealingrates and without the need to use separate sealing equipment fordifferent bag types.

To facilitate the discussion and description of the various embodimentsof the sealing apparatus, certain descriptive conventions may be used todescribe the relative position or location of the features that form theapparatus as well as relative direction. For example, the terms“upstream” and “downstream” will be used to describe the locationsrelative to a film path. For example, embodiments of the film-sealingsystem disclosed herein can include a film path that extends from aroll, through a set of tensioners, and then at least partially aroundthe outer surface of a former. Accordingly, the set of tensioners may bedescribed as downstream from the roll but upstream from the surface ofthe former. Moreover, the terms “retracted position” and “extendedposition” will be used to describe the static arrangement of theextendable linkages when the sealing jaw surfaces are engaged anddisengaged with one another. For example, a “retracted position”describes a position of the extendable linkages where the extendablelinkages are drawn in toward its resting position at close proximity toits respective housing and the sealing jaw surfaces are not in contactwith one another. An “extended position” describes a position of theextendable linkages where the extendable linkages are expanded out awayfrom its respective housing and the sealing jaw surfaces are in contactwith one another.

FIG. 1 depicts a bagmaker configured with a sealing apparatus inaccordance with an illustrative embodiment. Bagmaker 100 is a verticalform, fill, and seal machine that forms bags 102 from film 104 stored ona roll (not shown) and drawn along a film path 106 that extends througha set of tensioners 108, and over a forming collar 110 that allows thefilm 104 to wrap around the outer surface of a former 110. The film path106 is a predetermined set of positions along which film 104 travels:e.g., a path taken by film 104 through the bagmaker 100 as the film 104is manipulated from a generally planar form factor to a filled bag 102.The film 104 is drawn along the length of the former 112 by a set ofpull belts 114 while vertical sealer 116 seals the longitudinal edges ofthe film 104 together to form a tube of film. Transverse seals areformed in the tube of film by the novel sealing apparatus 200 locateddownstream from the pull belts 114 and on opposite sides of the filmpath 106.

In operation, partially formed bags are filled with product that arefirst weighed in weigher 118, and passed through funnel 120 and thenformer 112 before being deposited in a partially formed bag. Thepartially formed bag, now filled with product, is sealed on the upstreamend by sealing apparatus 200 and detached from the tube to form the bag102 filled with food product. In one embodiment, the sealing jaws of thesealing apparatus 200 have an integrated cutting surface that separatesa downstream bag 102 from the upstream tube of film 104 when thetransverse seal is formed, or shortly thereafter.

FIG. 2A depicts a sealing apparatus 200 in accordance with anillustrative embodiment. The sealing apparatus 200 can be generallydescribed as a pair of opposing sealing jaw units mounted on opposingsides of a film path for sealing and optionally cutting a tube of filmto form a bag. More specifically, the sealing apparatus 200 includes afirst sealing jaw unit 200 a mounted on a first side of film path 106,and a second sealing jaw unit 200 b mounted on a second side of filmpath 106 and oriented to oppose the first sealing jaw unit 200 a.

As shown in FIG. 2A, the first sealing jaw unit 200 a has a firstsealing jaw 208 a coupled to a first housing 204 a by a set ofextendable linkages 206 a. As used herein, the term “set of” means oneor more. Thus, a set of extendable linkages can mean one extendablelinkage, or two or more extendable linkages. As can be seen, the set ofextendable linkages 206 a in FIG. 2A includes more than one linkage,each of which is pivotally connected at its proximal end to the firsthousing 204 a. Likewise, each of the set of extendable linkages 206 a isalso pivotally coupled to a first sealing jaw 208 a at its distal end.Sealing apparatus 200 also includes a second sealing jaw unit 200 b thatincludes a second sealing jaw 208 b coupled to a second housing 204 b bya set of extendable linkages 206 b. Each of the set of extendablelinkages 206 b are pivotally connected to the second housing 204 b andthe second sealing jaw 208 b. In the exemplary embodiment of FIG. 2A,the first and second sealing jaw units 200 are identical and symmetricalacross the film path 106 located between the first and second sealingjaw units 200. The film path 106 in FIG. 2A is depicted to be linear andequidistant from the first and second sealing jaw units 200, however,the film path 106 may also flow along a non-linear path that may at somepoints be closer to one sealing jaw unit and at other points along thepath be closer to the other sealing jaw unit.

Extension and retraction of the set of extendable linkages 206 causesthe sealing surfaces 211 of the sealing jaws 208 to engage one anotherat one or more sealing locations that coincides with the film path 106.Motion is imparted to the set of extendable linkages 206 by actuatorsmounted within the housings 204, as can be seen in more detail in FIG.2B. In some embodiments, the actuators may be servo actuators. Inanother exemplary embodiment, the actuators are rotary actuators. Theincreased variability in the range of motion of the sealing jaws 208 isattributable, in part, to the rotatable joint 202 that divides each ofthe extendable linkages 206 into a primary proximal link 201 and aprimary distal link 203. In operation, the first and second sealing jawunits 200 are maintained at rest in a retracted position. Sealing isinitiated by one or more actuators that imparts motion to the set oflinkages 206, which rotates or pivots at one or more of the pivotalconnections or rotatable joints 202. For example, in some embodiments,the actuators may be rotary actuators. In another exemplary embodiment,the actuators are servo actuators. The motion is transferred to thesealing jaws 208, causing each of the sealing jaws 208 to proceed alonga predetermined sealing path until they meet at one or more of aplurality of sealing locations when the first and the second sealing jawunits 200 have achieved an extended position. Sealing occurs at the oneor more of the plurality of sealing locations when the two sealing jaws208 are in contact.

Because sealing occurs between the sealing surfaces 211 of the sealingjaws 208, the proper orientation of the sealing jaws 208 should bemaintained at least during the sealing process. In this illustrativeembodiment, proper orientation of the sealing jaws 208 are maintained bya plurality of secondary linkages 210. Each of the secondary linkages210 includes a secondary proximal link 207 attached to a joint lever 213that is in turn attached to a secondary distal link 205. Morespecifically, the secondary proximal link 207 is pivotally attached tothe housing 204 on one end and connected to a joint lever 213 on theother end. The fulcrum of the joint lever 213 is located at the joint212. The secondary proximal link 207 is maintained substantiallyparallel to the primary proximal link 201. Moreover a secondary distallink 205 is pivotally connected to the joint lever 213 on one end and adistal lever 214 on the other end. The primary distal link 203 ispivotally connected to the distal lever 214 at the fulcrum of the distallever and the sealing jaw 208 is fixed on the opposite side of thedistal lever 214 such that any movement in the primary distal link 203causes the secondary distal link 205 to be maintained substantiallyparallel to the primary distal link 203 and the sealing jaw 208orientation to be maintained. Alternatively, the orientation of thesealing jaw surfaces 211 may be modified while the sealing jaw unit 200is in use by actuating the secondary linkages 210 using a rotary orlinear actuator. In one aspect of the illustrative embodiment, thesecondary linkages 210 are actuated independently from the primarylinkages 206.

FIGS. 3A-B depicts a set of linear actuators used to actuate secondarylinkages in order to rotate the sealing jaw 208 in accordance with anillustrative embodiment. For example, linear actuator 230 is pivotablycoupled to the housing 204 and communicably coupled to control unit 502.Accordingly, the linear actuator 230 may extend or retract to actuatethe lever 213 which modifies the position of the secondary linkconnected to the distal lever 214. A fully extended position of thelinear actuator 230, is shown in FIG. 3A which corresponds to a sealingjaw that is rotated downward in a clockwise motion. A fully retractedposition of the linear actuator 230, is shown in FIG. 3B whichcorresponds to a sealing jaw 208 that is rotated upward in acounterclockwise motion. The linear actuator may be pneumatic,hydraulic, electrical or any available linear actuator known in theindustry. In one embodiment, a set of linear actuators 230 may be usedto actuate each set of secondary linkages 210. Alternatively, a singlelinear actuator 230 may be used to actuate both sets of secondarylinkages on each unit 200 a or 200 b using appropriate connections.

FIGS. 3C-D depicts a set of rotary actuators used to actuate secondarylinkages in order to rotate the sealing jaw 208 in accordance with anillustrative embodiment. For example, rotary actuator 232 is coupled tosecondary link 205 and communicably coupled to control unit 502.Accordingly, the rotary actuator 232 rotates in both the clockwise andcounterclockwise direction which actuates the secondary link 205 whichis connected to the distal lever 214. A rotation in the counterclockwisedirection is shown in FIG. 3C which corresponds to a sealing jaworiented in an upward, counterclockwise position. A rotation in theclockwise direction is shown in FIG. 3D which corresponds to a sealingjaw oriented in a downward, clockwise position. In one embodiment, a setof rotary actuators may be used to actuate each set of secondarylinkages. Alternatively, a single rotary actuator may be used to actuateboth sets of secondary linkages on each unit 200 a or 200 b usingappropriate connections. In another illustrative embodiment, the rotaryactuator may be used at location 214. For example, a rotary actuator atlocation 214 would eliminate the need for the sets of secondary linkagesbecause the orientation of the seal jaw may be controlled directly onthe lever 214 on which the sealing jaw is coupled to. In one embodiment,the sealing jaw surfaces 211 are rounded to accommodate a rotationalmotion upon contact with one another.

In addition to modifying sealing jaw orientation during the sealingprocess, sealing paths and sealing locations may also be modifiedin-process as illustrated in FIGS. 4A to 4D. For example, FIG. 4Adepicts a reciprocating motion in which the first and second sealingjaws 208 repeatedly meet in the same sealing location 301 using sealingjaw path 300 a and returning substantially along the same path 300 b. Inan exemplary embodiment, the sealing jaw path 300 a starts with thefirst and second sealing jaws 208 in retracted positions, then movesinto extended positions and returns back to retracted positions. Inanother exemplary embodiment, rather than returning to retractedpositions, an open sealing jaw clearance 302 between the first andsecond seal jaws is maintained to allow the film to continue down filmpath 106 before the next sealing motion occurs. The clearance 302 mayoptionally be adjusted based on any number of factors including film 104thickness and film path orientation.

FIG. 4B depicts a rotary sealing motion in which the first and secondsealing jaws 208 rotate in opposing directions and meet at a location305 within the volume 500 along path 304 a. The film path 106 coincideswith the tangential direction of both the first and second sealing jawpaths 304 a along the meeting location 305 of the first and secondsealing jaws 208. The sealing jaw return path 304 b completes therotational motion back to the starting point of the sealing jaws 208. Inan exemplary embodiment, the starting point is the retracted position ofthe first and second sealing jaws. In another exemplary embodiment therotary motion maintains a clearance 302 instead of returning to aretracted position.

FIG. 4C depicts a sealing motion in which the sealing jaws 208 extend ina linear path 306 a that meets on a location 307 along the film 104 andmoves along the film path 106 shown in path 306 b at a rate consistentwith the rate of the film 104 to prevent disrupting the film 104 alongthe film path 106 or in order to facilitate draw-down of the film 104along the film path 106. The sealing jaws 208 then return to theoriginal retracted positions using sealing jaw path 306 c. In anotherexemplary embodiment, the sealing jaws 208 do not return to the originalretracted position and instead maintains a clearance 302 betweensealing.

FIG. 4D depicts a sealing pattern in which the sealing jaws meet andretract at a location at one point 308 a along film path 106 followingsealing jaw path 310 a during extension and sealing jaw path 310 bduring a retraction before following sealing jaw path 310 c to alocation downstream of location 308 a along the film path 106 at a rategreater than the rate of the continuous film 104. The first and secondsealing jaws 208 then meet again at the downstream meeting location 308b along the film path 106 using sealing jaw path 310 d before returningto the retracted position using sealing jaw path 310 e.

Although FIGS. 4A-D depict meeting locations that are equidistant fromthe first and second sealing jaws, the meeting locations do notnecessarily have to be equidistant from the first and second sealingjaws. For example, the meeting locations may be closer to the firstsealing jaw or it may be closer to the second sealing jaw depending onthe position of the film. Moreover, the first sealing jaw path does notnecessarily have to be the same as the second sealing jaw path withrespect to the film. Each sealing jaw may move in different patterns andspeeds from one another depending on the position of the film or thetype of bag. In one embodiment, the rate at which the sealing jaws 208engage and disengage one another may be adjusted based on the rate ofthe film 104 moving along the film path 106. In another embodiment, theperiod of contact time between the first and second seal jaw surfaces211 may be adjusted based on the type of film 104 used. For example, thethickness of the film 104, the number of layers of the film 104, and thetype of material or resin of the film 104.

As depicted in FIG. 2A, the first and second sealing jaws 208 a and 208b, are each configured with sealing elements 209 a and 209 b,respectively. For example, sealing elements may be heating elements orultrasonic elements which may be configured to sealing jaws using anyconventional method or design known in the industry. The sealingelements 209 may heat either sealing jaws 208 or both sealing jaws to arange of temperatures necessary to heat seal the film 104 upon contactwith both of the sealing jaws 208. The temperature of the sealing jawsurfaces 211 may be adjusted in synchronization with one another, or thetemperature of the sealing jaws surfaces 211 may be adjustedindependently from one another. In an exemplary embodiment, thetemperature of the sealing jaw surfaces 211 may be adjusted based on thetype bag 102 or the type of film 104 used for the bag 102.

Moreover contact pressure and contact time may also be adjusted based onsimilar factors such as the type bag 102 or the type of film 104 usedfor the bag 102. For example, the thickness of the film 104, the numberof layers of the film 104, and the type of material or resin of the film104. In an exemplary embodiment, the contact pressure or “jaw force” maybe about 500 to 2,000 lbf, the contact time required to maintain contactbetween the jaws may be 70 to 500 milliseconds, the width of the firstand second sealing jaws may be about 0.25″ to about 1.5″, and the weightof the first and second sealing jaws may be about 6 to 7 lbs each.

FIG. 2B shows an alternate angled perspective of a sealing jaw unit 200,for example the first sealing jaw unit 200 a with four extendablelinkages 206 along with actuators 220 that drive the extendable linkages206. In one embodiment, each rotary actuator 220 drives a shaft 222located in the first housing 204 a that is connected to a pair ofextendable linkages 206. Similarly, one or more actuators 220 arelocated in the second housing 204 b. For example, a system with eighttotal extendable linkages 206 may require a total of four actuators 220.In the illustrative embodiment shown in FIG. 2B, the actuator 220 drivesthe pair of extendable linkages 206 by rotating the shaft 222 in eitherdirection. The extendable linkages 206 move the sealing jaws 208 over anumber of positions while maintaining the sealing jaws 208 in the sameorientation such that the sealing jaw surfaces 211 are substantiallyparallel to one another. In one embodiment, the surface orientation maybe achieved using a set of secondary links such as 205 a, 205 b, 207 a,and 207 b shown in FIG. 2A and can be configured to all of theextendable linkages 206 or can be configured to a select number ofextendable linkages. The illustrative embodiment shown in FIG. 2A, forexample, shows the secondary link structure installed on four out ofeight extendible linkages. Moreover, maintaining an orientation at adistal end of a similar extendable linkage structure may also beachieved using any method known in the industry. Consequently, the firstand second sealing jaws are oriented such that the first and secondsealing jaw surfaces 211 a and 211 b, respectively, are parallel to oneanother on opposing sides of the film path 106. Alternatively, theorientation of the sealing jaw surfaces may be modified while thesealing jaw unit is in use by actuating the secondary linkages using arotary or linear actuator as shown in FIG. 3A to D.

FIG. 5 depicts a schematic view of the invention in the context of afilm sealing environment 501 in accordance with an illustrativeembodiment. The film 104 is depicted continuously flowing along a filmpath 106 between the first and second sealing jaw unit 200. The sealingjaw area defining the locations in which the sealing jaws may meet isdefined in an area 500 between the first and second sealing jaw units200. In one embodiment, the position within the plurality of locationsthat the first and second sealing jaws 208 may engage in area 500 isadjusted depending on the position of the film path 106.

A control unit 502 is able to control the motion of the first and secondsealing jaw units 200 using a communication link 506 such as a cable ora wireless signal or any communication method known in the art.

More particularly, the control unit 502 is coupled via the communicationlink (or signal) 506 to the actuators 220 located in each of the first204 a and second 204 b housing. The signal 506 causes the actuators 220to rotate in either direction in order to drive the shaft 222 which alsorotates the extendable linkages 206. The first set of linkages 206 a maybe driven independently from the second set of extendable linkages 206b.

Each of the first 204 a and second 204 b housings are mounted onvertical frame supports 504. It can be appreciated that the first 204 aand second 204 b housings may be mounted on vertical frame supports,platforms, rails, vertical walls, and/or on the floor.

FIG. 6 is a flowchart of a method for sealing a film in accordance withan illustrative embodiment. The method may be performed by a sealingapparatus, such as sealing apparatus 100 in FIG. 1. The method includesthe steps of:

providing a first sealing jaw unit on a first side of a film path with afirst sealing jaw coupled to a distal end of its first set of extendablelinkages in step 601; For example, the extendable linkages 206 may havea primary proximal link 201 and a primary distal link 203 coupled to oneanother at a rotatable joint 202.

providing a second sealing jaw unit on a second side of the film pathwith a second sealing jaw coupled to a distal end of its second set ofextendable linkages, in which the first sealing jaw and the secondsealing jaw are extendable to allow the first sealing surface to engagethe second sealing surface in a number of potential sealing locations instep 602; For example, the first sealing surface 211 a may be heatedwith or separately from the second sealing surface 211 b. Moreover thesealing surface may be configured with an ultrasonic element.

determining a first sealing path for the first sealing jaw in step 603;For example, the first sealing path may be modified to accommodate thebag type.

determining a second sealing path for the second sealing jaw so thatmovement of the first sealing jaw along the first sealing path andmovement of the second sealing jaw along the second sealing path causesthe first sealing jaw and the second sealing jaw to meet at any one ormore of the plurality of sealing locations located along the film pathin step 604; For example, the first sealing path may be similar inpattern compared to the second sealing path, or it may follow a distinctpattern from the second sealing path.

extending a film along the film path in step 605; and

For example, FIG. 4C shows the sealing path 306 a, 306 b, and 306 c inwhich the sealing surfaces 211 meet at location 307 along the film path106 and move along the film direction to draw the film down along thefilm path 106.

sealing the film between the two sealing jaws at any one or more of aplurality of sealing locations in step 606.

For example, the sealing jaws may seal repeatedly at the same seallocation as shown in FIG. 4A, or sealing may occur at location 308 a andthen again at a downstream location 308 b as shown in FIG. 4D.

Additional Embodiments

The following descriptive embodiments are offered as further support ofthe disclosed invention:

In a first embodiment, novel aspects described in the present disclosureare directed to a sealing apparatus comprising: a first sealing jaw unitmounted on a first side of a film path, wherein the first sealing jawunit comprises a first sealing jaw coupled to a distal end of a firstset of extendable linkages, and wherein the first sealing jaw has afirst sealing surface; a second sealing jaw unit mounted on an oppositeside of the film path, wherein the second sealing jaw comprises a secondsealing jaw coupled to a distal end of a second set of extendablelinkages, wherein the second sealing jaw comprises a second sealingsurface, and wherein the first sealing jaw and the second sealing jaware extendable to allow the first sealing surface to engage the secondsealing surface along one of a plurality of sealing paths; and a controlunit communicatively coupled to the first sealing jaw unit and thesecond sealing jaw unit, wherein the control unit controls movement ofthe first sealing jaw and the second sealing jaw to engage the first andthe second sealing surfaces along one of a plurality of sealing paths.

In another aspect of the first embodiment, the sealing apparatuscomprising: a first sealing jaw unit mounted on a first side of a filmpath, wherein the first sealing jaw unit comprises a first sealing jawcoupled to a distal end of a first set of extendable linkages, andwherein the first sealing jaw has a first sealing surface; a secondsealing jaw unit mounted on an opposite side of the film path, whereinthe second sealing jaw comprises a second sealing jaw coupled to adistal end of a second set of extendable linkages, wherein the secondsealing jaw comprises a second sealing surface, and wherein the firstsealing jaw and the second sealing jaw are extendable to allow the firstsealing surface to engage the second sealing surface along one of aplurality of sealing paths; a control unit communicatively coupled tothe first sealing jaw unit and the second sealing jaw unit, wherein thecontrol unit controls movement of the first sealing jaw and the secondsealing jaw to engage the first and the second sealing surfaces alongone of a plurality of sealing paths; and further comprises one or morelimitations selected from the following:

wherein the first set of extendable linkages are rotatably connected toa first housing, wherein the second set of extendable linkages arerotatably connected to a second housing, and wherein each of theextendable linkages further comprises: a primary proximal link; aprimary distal link coupled to the primary proximal link at a rotatablejoint;

a first plurality of actuators mounted within the first housing andcoupled with the first set of extendable linkages, and a secondplurality of actuators mounted within the second housing and coupledwith the second set of extendable linkages; and wherein the firstplurality of actuators causes the first sealing jaw to travel along afirst sealing path, and wherein the second plurality of actuators causesthe second sealing jaw to travel along a second sealing pathintersecting the first sealing path at one or more of the plurality ofsealing locations;

a first set of secondary linkages coupled with the first set ofextendable linkages, wherein the first set of secondary linkagesmaintains an orientation of the first sealing jaw; a second set ofsecondary linkages coupled with the second set of extendable linkages,wherein the second set of secondary linkages maintains an orientation ofthe second sealing jaw; wherein the first sealing surface is maintainedparallel to the second sealing surface;

a first set of secondary linkages coupled with the first set ofextendable linkages, wherein the first set of secondary linkages isconfigured to modify the orientation of the first sealing jaw; a secondset of secondary linkages coupled with the second set of extendablelinkages, wherein the second set of secondary linkages is configured tomodify the orientation of the second sealing jaw;

a first set of one or more linear actuators pivotably coupled to a firsthousing and coupled with the first set of secondary linkages, and asecond set of one or more of linear actuators pivotably coupled to asecond housing and coupled with the second set of secondary linkages;and wherein the first set of linear actuators actuates the first set ofsecondary linkages and causes the first sealing jaw to rotate, andwherein the second set of linear actuators actuates the second set ofsecondary linkages and causes the second sealing jaw to rotate.

a first set of one or more rotary actuators coupled with the first setof secondary linkages, and a second set of one or more rotary actuatorscoupled with the second set of secondary linkages; and wherein the firstset of rotary actuators actuates the first set of secondary linkages andcauses the first sealing jaw to rotate, and wherein the second set ofrotary actuators actuates the second set of secondary linkages andcauses the second sealing jaw to rotate;

wherein the control unit controls each of the actuators independently;

wherein each actuator powers a pair of extendable linkages;

a first sealing element coupled with the first sealing surface; and asecond sealing element coupled with the second sealing surface;

wherein each of the set of extendable linkages comprises two pairs ofextendable linkages;

wherein the plurality of sealing locations is defined by an area betweenthe first and second sealing jaw units with dimensions perpendicular andparallel to the film path;

wherein each of the plurality of actuators comprises two actuators;

wherein the first and second sealing elements are heating elements;

wherein the first and second sealing elements are ultrasonic elements;

wherein the first and second plurality of actuators are servo actuators;and

wherein the first and second plurality of actuators are rotaryactuators.

In a second embodiment, novel aspects of the present disclosure aredirected to a film sealing method comprising the steps of: providing afirst sealing jaw unit on a first side of a film path, wherein the firstsealing jaw unit comprises a first sealing jaw coupled to a distal endof a first set of extendable linkages, and wherein the first sealing jawhas a first sealing surface; providing a second sealing jaw unit on asecond side of the film path, wherein the second sealing jaw comprises asecond sealing jaw coupled to a distal end of a second set of extendablelinkages, wherein the second sealing jaw comprises a second sealingsurface, and wherein the first sealing jaw and the second sealing jaware extendable to allow the first sealing surface to engage the secondsealing surface at one of a plurality of sealing locations; determininga first sealing path for the first sealing jaw; determining a secondsealing path for the second sealing jaw, wherein movement of the firstsealing jaw along the first sealing path and movement of the secondsealing jaw along the second sealing path causes the first sealing jawand the second sealing jaw to meet at one of the plurality of sealinglocations located along the film path; extending a film along the filmpath; and sealing the film between the first sealing jaw and the secondsealing jaw at one of the plurality of sealing locations.

In another aspect of the second embodiment, novel aspects of the presentdisclosure are directed to a method wherein the first sealing path andthe second sealing path are defined/determined based on a bag type, themethod further comprising one or more limitations selected from thefollowing:

wherein sealing the film between the first sealing jaw and the secondsealing jaw further comprises: moving the first sealing jaw along thefirst sealing path; moving the second sealing jaw along the secondsealing path;

wherein the first set of extendable linkages are rotatably connected toa first housing, wherein the second set of extendable linkages arerotatably connected to a second housing, and wherein each of theextendable linkages further comprises: a primary proximal link; aprimary distal link coupled to the primary proximal link at a rotatablejoint;

wherein moving the first sealing jaw along the first sealing pathfurther comprises extending the first sealing jaw along a firstextension path and retracting the first sealing jaw along a first returnpath; and wherein moving the second sealing jaw along the second sealingpath further comprises extending the second sealing jaw along a secondextension path and retracting the second sealing jaw along a secondreturn path;

wherein the first return path and the second return path coincidewith/extend along at least a portion of the film path;

creating a sealing pattern wherein the first and second sealing jawsmeet and retract in an upstream position of the film path, and whereinthe first and second sealing jaws meet and retract in a downstreamposition of the film path;

selecting a bag type; and modifying the first sealing path and thesecond sealing path to accommodate the bag type;

maintaining a first sealing surface of the first sealing jaw parallel toa second sealing surface of the second sealing jaw;

heating the first sealing surface, or the second sealing surface, orcombinations thereof; and

activating an ultrasonic sealer on the first sealing surface, or thesecond sealing surface, or combinations thereof.

Although the present disclosure has provided many examples of systems,apparatuses, and methods, it should be understood that the components ofthe systems, apparatuses and method described herein are compatible andadditional embodiments can be created by combining one or more elementsfrom the various embodiments described herein. As an example, in someembodiments, a method described herein can further comprise one or moreelements of a system described herein or a selected combination ofelements from any combination of the systems or apparatuses describedherein. Furthermore, in some embodiments, a method described herein canfurther comprise using a system described herein, using one or moreelements of a system described herein, or using a selected combinationof elements from any combination of the systems described herein.

Although embodiments of the invention have been described with referenceto several elements, any element described in the embodiments describedherein are exemplary and can be omitted, substituted, added, combined,or rearranged as applicable to form new embodiments. A skilled person,upon reading the present specification, would recognize that suchadditional embodiments are effectively disclosed herein. For example,where this disclosure describes characteristics, structure, size, shape,arrangement, or composition for an element or process for making orusing an element or combination of elements, the characteristics,structure, size, shape, arrangement, or composition can also beincorporated into any other element or combination of elements, orprocess for making or using an element or combination of elementsdescribed herein to provide additional embodiments. For example, itshould be understood that the method steps described herein areexemplary, and upon reading the present disclosure, a skilled personwould understand that one or more method steps described herein can becombined, omitted, re-ordered, or substituted.

Additionally, where an embodiment is described herein as comprising someelement or group of elements, additional embodiments can consistessentially of or consist of the element or group of elements. Also,although the open-ended term “comprises” is generally used herein,additional embodiments can be formed by substituting the terms“consisting essentially of” or “consisting of.”

Where language, for example, “for” or “to”, is used herein inconjunction with an effect, function, use or purpose, an additionalembodiment can be provided by substituting “for” or “to” with“configured for/to” or “adapted for/to.”

Additionally, when a range for a particular variable is given for anembodiment, an additional embodiment can be created using a subrange orindividual values that are contained within the range. Moreover, when avalue, values, a range, or ranges for a particular variable are givenfor one or more embodiments, an additional embodiment can be created byforming a new range whose endpoints are selected from any expresslylisted value, any value between expressly listed values, and any valuecontained in a listed range. For example, if the application were todisclose an embodiment in which a variable is 1 and a second embodimentin which the variable is 3-5, a third embodiment can be created in whichthe variable is 1.31-4.23. Similarly, a fourth embodiment can be createdin which the variable is 1-5.

As used herein, examples of “substantially” include: “more so than not,”“mostly,” and “at least 30, 40, 50, 60, 70, 80, 90, 95, 96, 97, 98 or99%” with respect to a referenced characteristic. With respect tovectors, directions, movements or angles, that are “substantially” inthe same direction as or parallel to a reference vector, direction,movement, angle or plane, “substantially” can also mean “at least acomponent of the vector, direction, movement or angle specified isparallel to the reference vector, direction, movement, angle or plane,”although substantially can also mean within plus or minus 45, 40, 35,30, 25, 20, 15, 10, 5, 4, 3, 2, or 1 degrees of the reference vector,direction, movement, angle or plane.

As used herein, examples of “about” and “approximately” include aspecified value or characteristic to within plus or minus 30, 25, 20,15, 10, 5, 4, 3, 2, or 1% of the specified value or characteristic.

While this invention has been particularly shown and described withreference to preferred embodiments, it will be understood by thoseskilled in the art that various changes in form and detail may be madetherein without departing from the spirit and scope of the invention.The inventors expect skilled artisans to employ such variations asappropriate, and the inventors intend the invention to be practicedotherwise than as specifically described herein. Accordingly, thisinvention includes all modifications and equivalents of the subjectmatter recited in the claims appended hereto as permitted by applicablelaw. Moreover, any combination of the above-described elements in allpossible variations thereof is encompassed by the invention unlessotherwise indicated herein or otherwise clearly contradicted by context.

We claim:
 1. A sealing apparatus comprising: a first sealing jaw unit mounted on a first side of a film path, wherein the first sealing jaw unit comprises a first sealing jaw coupled to a distal end of a first set of extendable linkages, and wherein the first sealing jaw has a first sealing surface; a second sealing jaw unit mounted on an opposite side of the film path, wherein the second sealing jaw comprises a second sealing jaw coupled to a distal end of a second set of extendable linkages, wherein the second sealing jaw comprises a second sealing surface, and wherein the first sealing jaw and the second sealing jaw are extendable to allow the first sealing surface to engage the second sealing surface at each of a plurality of sealing locations using one of a plurality of sealing paths; and a control unit communicatively coupled to the first sealing jaw unit and the second sealing jaw unit, wherein the control unit controls movement of the first sealing jaw and the second sealing jaw to engage the first and the second sealing surfaces at one or more of the plurality of sealing locations using one of a plurality of sealing paths.
 2. The sealing apparatus of claim 1, wherein the first set of extendable linkages are rotatably connected to a first housing, wherein the second set of extendable linkages are rotatably connected to a second housing, and wherein each of the extendable linkages further comprises: a primary proximal link; a primary distal link coupled to the primary proximal link at a rotatable joint.
 3. The sealing apparatus of claim 2, further comprising a first plurality of actuators mounted within the first housing and coupled with the first set of extendable linkages, and a second plurality of actuators mounted within the second housing and coupled with the second set of extendable linkages; and wherein the first plurality of actuators causes the first sealing jaw to travel along a first sealing path, and wherein the second plurality of actuators causes the second sealing jaw to travel along a second sealing path intersecting the first sealing path at one or more of the plurality of sealing locations.
 4. The sealing apparatus of claim 1, further comprising: a first set of secondary linkages coupled with the first set of extendable linkages, wherein the first set of secondary linkages maintains an orientation of the first sealing jaw; a second set of secondary linkages coupled with the second set of extendable linkages, wherein the second set of secondary linkages maintains an orientation of the second sealing jaw; wherein the first sealing surface is maintained parallel to the second sealing surface.
 5. The sealing apparatus of claim 1, further comprising: a first set of secondary linkages coupled with the first set of extendable linkages, wherein the first set of secondary linkages is configured to modify the orientation of the first sealing jaw; a second set of secondary linkages coupled with the second set of extendable linkages, wherein the second set of secondary linkages is configured to modify the orientation of the second sealing jaw.
 6. The sealing apparatus of claim 5, further comprising a first set of linear actuators pivotably coupled to a first housing and coupled with the first set of secondary linkages, and a second set of linear actuators pivotably coupled to a second housing and coupled with the second set of secondary linkages; and wherein the first set of linear actuators actuates the first set of secondary linkages and causes the first sealing jaw to rotate, and wherein the second set of linear actuators actuates the second set of secondary linkages and causes the second sealing jaw to rotate.
 7. The sealing apparatus of claim 5, further comprising a first set of rotary actuators coupled with the first set of secondary linkages, and a second set of rotary actuators coupled with the second set of secondary linkages; and wherein the first set of rotary actuators actuates the first set of secondary linkages and causes the first sealing jaw to rotate, and wherein the second set of rotary actuators actuates the second set of secondary linkages and causes the second sealing jaw to rotate.
 8. The sealing apparatus of claim 3, wherein the control unit controls each of the actuators independently.
 9. The sealing apparatus of claim 3, wherein each actuator powers a pair of extendable linkages.
 10. The sealing apparatus of claim 1, further comprising: a first sealing element coupled with the first sealing surface; and a second sealing element coupled with the second sealing surface.
 11. The sealing apparatus of claim 1, wherein each of the set of extendable linkages comprises two pairs of extendable linkages.
 12. The sealing apparatus of claim 3, wherein the plurality of sealing locations is defined by an area between the first and second sealing jaw units with dimensions perpendicular and parallel to the film path.
 13. The sealing apparatus of claim 3, wherein each of the plurality of actuators comprises two actuators.
 14. The sealing apparatus of claim 10, wherein the first and second sealing elements are heating elements.
 15. The sealing apparatus of claim 10, wherein the first and second sealing elements are ultrasonic elements.
 16. A film sealing method comprising the steps of: providing a first sealing jaw unit on a first side of a film path, wherein the first sealing jaw unit comprises a first sealing jaw coupled to a distal end of a first set of extendable linkages, and wherein the first sealing jaw has a first sealing surface; providing a second sealing jaw unit on a second side of the film path, wherein the second sealing jaw comprises a second sealing jaw coupled to a distal end of a second set of extendable linkages, wherein the second sealing jaw comprises a second sealing surface, and wherein the first sealing jaw and the second sealing jaw are extendable to allow the first heated surface to engage the second heated surface at one of a plurality of sealing locations; extending a film along a film path; and sealing the film between the first sealing jaw and the second sealing jaw at any one or more of a plurality of sealing locations; determining a first sealing path for the first sealing jaw; determining a second sealing path for the second sealing jaw, wherein movement of the first sealing jaw along the first sealing path and movement of the second sealing jaw along the second sealing path causes the first sealing jaw and the second sealing jaw to meet at any one or more of the plurality of sealing locations located along the film path; sealing the film between the first sealing jaw and the second sealing jaw at any one or more of the plurality of sealing locations.
 17. The method of claim 16, wherein moving the first sealing jaw along the first sealing path further comprises extending the first sealing jaw along a first extension path and retracting the first sealing jaw along a first return path; and wherein moving the second sealing jaw along the second sealing path further comprises extending the second sealing jaw along a second extension path and retracting the second sealing jaw along a second return path.
 18. The method of claim 17, wherein the first return path and the second return path coincide with/extend along at least a portion of the film path.
 19. The method of claim 17, further comprising: creating a sealing pattern wherein the first and second sealing jaws meet and retract in an upstream position of the film path, and wherein the first and second sealing jaws meet and retract in a downstream position of the film path.
 20. The method of claim 16, further comprising: selecting a bag type; and modifying the first sealing path and the second sealing path to accommodate the bag type. 